Eddy-current probe

ABSTRACT

An eddy-current probe according to the present invention comprises: a substrate having a first surface facing to a subject to be tested and a second surface opposite to said first surface; an exciting coil formed on the second surface, having a pair of current lines in parallel with each other through which exciting currents flow in opposite directions to each other during testing, for generating an alternate magnetic field applied to the subject by the exciting currents; and at least one eddy-current sensor positioned on a central axis between the pair of current lines on the second surface of the substrate, for detecting a magnetic field generated newly from the subject by an eddy-current induced by the alternate magnetic field. The substrate has a non-planar form having at least one convex-surface portion on the first surface, and the at least one eddy-current sensor is formed on at least one concave-surface portion formed on the second surface, which is corresponding to the at least one convex-surface portion.

PRIORITY CLAIM

This application is a divisional application of application Ser. No.11/203,252, filed Aug. 15, 2005, which is a divisional application ofapplication Ser. No. 10/938,541, filed Sep. 13, 2004.

This application claims priority from Japanese patent application No.2003-326174, filed on Sep. 18, 2003, which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an eddy-current probe that is able todetect object's shapes, defects and so on nondestructively.

2. Description of the Related Art

Eddy-current testing (ECT) technique is frequently utilized fornondestructive testing of distorted surfaces of important metal machineparts used in a nuclear power plant, an airplane and so on, such asturbine blades, various pipes and airplane wings. Generally, such an ECTprobe using the eddy-current includes mainly an exciting coil and adetector coil for detecting a magnetic field based on an eddy-currentinduced by an alternating magnetic field generated by the excited coil.Such a technique is described in for example, Japanese PatentPublications Nos. 07-083884A, 09-189682A, 11-248685A and 2002-090490A.

Further, a planar-type ECT probe for inspecting printed circuit boardsis proposed, including a meander-type exciting coil and a pick-up coilfor the eddy-current detection which are formed on a flexible planarsubstrate. Such a probe is described in for example, T. Miyagoshi, D.Kacprzak, S. Yamada and M. Iwahara, “Feasibility of Inspecting Defectsin Printed Circuit Boards by Using Eddy-Current Testing Techniques”,Journal of the Magnetics Society of Japan, Vol. 23, No. 4-2, pp.1613-1616, 1999, and S. Yamada and M. Iwahara, “Trend of DetectionTechniques Using Planar-Type Micro-Eddy-Current Testing Probes”, Journalof the Magnetics Society of Japan, Vol. 23, No. 7, pp. 1817-1825, 1999.

Recently, in such an ECT probe, an element for detecting theeddy-current, that is, an eddy-current sensor has been intended to beminiaturized, and to be improved in resolution and sensitivity. In orderto improve its detecting resolution, as well as to miniaturize it, theECT probe has been required to have less spacing between the sensor anda subject.

It is difficult for the planar-type ECT probe using a planar substrateto constantly keep the spacing between the surfaces of the substrate andof a subject much small. In some cases, the surfaces of the substrateand of the subject are almost in contact with each other. Further, whenthe subject has distorted surfaces, the ECT probe using a flexible thinsubstrate is desirable to be utilized to follow the surfaces smoothly.However, it is impossible to follow such a flexible substrate in nocontact with the subject's surface.

When the surfaces of the substrate used in the planar-type ECT probe andof the subject are almost in contact with each other, an adsorptionphenomenon (sticktion) is likely to occur between the surfaces of thesubstrate and of the subject.

When the sticktion occurs, some external-force application is needed toremove the probe substrate from the subject's surface against thesticktion. The application is likely to damage the probe substrate. Theweaker is the strength of the substrate, the damage by the sticktionoccurs more frequently. Because the flexible substrate has a smallthickness and a weak mechanical strength, the durability and lifetime ofthe planar-type ECT probe depend largely on the occurrence of thesticktion, especially in the measurement of the distorted surface wherethe substrate inevitably has a contact with the subject's surface.

This problem tends greatly to appear in micro-defect detection on thesmooth surface of the substrate.

BRIEF SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide aneddy-current probe for high resolution testing, possessing very highperformances of the durability and lifetime by reducing an occurrenceprobability of the sticktion.

An eddy-current probe according to the present invention comprises: asubstrate having a first surface facing to a subject to be tested and asecond surface opposite to the first surface; an exciting coil formed onthe second surface, having a pair of current lines in parallel with eachother through which exciting currents flow in opposite directions toeach other during testing, for generating an alternate magnetic fieldapplied to the subject by the exciting currents; and at least oneeddy-current sensor positioned on a central axis between the pair ofcurrent lines on the second surface of the substrate, for detecting amagnetic field generated newly from the subject by an eddy-currentinduced by the alternate magnetic field. Especially, according to thepresent invention, the substrate has a non-planar form having at leastone convex-surface portion on the first surface, and the at least oneeddy-current sensor is formed on at least one concave-surface portionformed on the second surface, which is corresponding to the at least oneconvex-surface portion.

Because the first surface of the substrate facing to the subject (themeasurement surface) has a non-planar form having the at least oneconvex-surface portion and therefore has a small facing/contact areawith the subject's surface, the sticktion hardly occurs. Even if thesticktion occurs, much less external-force application should be neededto remove the probe from the subject's surface against the sticktion.Consequently, a damage probability by the sticktion is drasticallyreduced, and therefore, the durability and lifetime can be improved in alarge extent. Further, because the at least one eddy-current sensor isformed on the at least one concave-surface portion formed on the secondsurface (the opposite surface to the measurement surface), which iscorresponding to the at least one convex-surface portion, the distancebetween the subject's surface and the eddy-current sensor does notincrease, and therefore, a high performance of resolution is provided.

Preferably, the at least one convex-surface portion has a waved convexform where the substrate is curved along a traverse direction (Xdirection). In the case, it is preferable that the at least oneconvex-surface portion is a single convex-surface portion or a pluralityof convex-surface portions.

It is also preferable that the substrate is a flexible substrate.

Further, an eddy-current probe according to the present inventioncomprises: a substrate having a first surface facing to a subject to betested and a second surface opposite to the first surface; an excitingcoil formed on the second surface, having a pair of current lines inparallel with each other through which exciting currents flow inopposite directions to each other during testing, for generating analternate magnetic field applied to the subject by the excitingcurrents; and at least one eddy-current sensor positioned on a centralaxis between the pair of current lines on the second surface of thesubstrate, for detecting a magnetic field generated newly from thesubject by an eddy-current induced by the alternate magnetic field.Especially, according to the present invention, the first surface of thesubstrate has a plurality of concaves and convexes.

Because the first surface of the substrate (the measurement surface) hasa plurality of concaves and convexes, the sticktion hardly occurs. Evenif the sticktion occurs, much less external-force application should beneeded to remove the probe from the subject's surface against thesticktion. Consequently, a damage probability by the sticktion isdrastically reduced. Therefore, the durability and lifetime of theeddy-current probe show no decrease, even when a high resolution isobtained by putting the measurement surface of the probe toward thesubject's surface as closely as possible to minimize the distancebetween the subject's surface and the eddy-current sensor.

Preferably, the surface having a plurality of concaves and convexes is arough surface by such as a blast finishing or an embossed surface.

Preferably, a lubricant layer, a diamond-like carbon (DLC) layer, orboth of a DLC layer and a lubricant layer are formed on the firstsurface having a plurality of concaves and convexes. The lubricantlayer, the DLC layer, or both of the DLC layer and the lubricant layerformed on the surface can prevent the sticktion more surely, and reducethe wear-outs of the measurement surface of the substrate and of thesubject's surface.

Furthermore, an eddy-current probe according to the present inventioncomprises: a substrate having a first surface facing to a subject to betested and a second surface opposite to the first surface; an excitingcoil formed on the second surface, having a pair of current lines inparallel with each other through which exciting currents flow inopposite directions to each other during testing, for generating analternate magnetic field applied to the subject by the excitingcurrents; and at least one eddy-current sensor positioned on a centralaxis between the pair of current lines on the second surface of thesubstrate, for detecting a magnetic field generated newly from thesubject by an eddy-current induced by the alternate magnetic field.Especially, according to the present invention, the first surface of thesubstrate has a plurality of grooves.

Because the first surface of the substrate (the measurement surface) hasa plurality of grooves, the sticktion hardly occurs. Even if thesticktion occurs, much less external-force application should be neededto remove the probe from the subject's surface against the sticktion.Consequently, a damage probability by the sticktion is drasticallyreduced. Therefore, the durability and lifetime of the eddy-currentprobe show no decrease, even when a high resolution is obtained byputting the measurement surface of the probe toward the subject'ssurface as closely as possible to minimize the distance between thesubject's surface and the eddy-current sensor.

Preferably, a plurality of grooves are grooves extended along a traversedirection (X direction) of the substrate, grooves extended along alongitudinal direction (Z direction) of the substrate, or groovesextended along an oblique direction to the traverse direction (Xdirection) of the substrate.

Preferably, a lubricant layer, a DLC layer, or both of a DLC layer and alubricant layer are formed on the first surface having a plurality ofgrooves. The lubricant layer, the DLC layer, or both of the DLC layerand the lubricant layer formed on the surface can prevent the sticktionmore surely, and reduce the wear-outs of the measurement surface of thesubstrate and of the subject's surface.

Further, an eddy-current probe according to the present inventioncomprises: a substrate having a first surface facing to a subject to betested and a second surface opposite to the first surface; an excitingcoil formed on the second surface, having a pair of current lines inparallel with each other through which exciting currents flow inopposite directions to each other during testing, for generating analternate magnetic field applied to the subject by the excitingcurrents; and at least one eddy-current sensor positioned on a centralaxis between the pair of current lines on the second surface of thesubstrate, for detecting a magnetic field generated newly from thesubject by an eddy-current induced by the alternate magnetic field.Especially, according to the present invention, the first surface of thesubstrate has a plurality of holes.

Because the first surface of the substrate (the measurement surface) hasa plurality of holes, the sticktion hardly occurs. Even if the sticktionoccurs, much less external-force application should be needed to removethe probe from the subject's surface against the sticktion.Consequently, a damage probability by the sticktion is drasticallyreduced. Therefore, the durability and lifetime of the eddy-currentprobe show no decrease, even when a high resolution is obtained byputting the measurement surface of the probe toward the subject'ssurface as closely as possible to minimize the distance between thesubject's surface and the eddy-current sensor.

Preferably, the holes are blind holes or through holes.

Preferably, a lubricant layer, a DLC layer, or both of a DLC layer and alubricant layer are formed on the first surface having a plurality ofholes. The lubricant layer, the DLC layer, or both of the DLC layer andthe lubricant layer formed on the surface can prevent the sticktion moresurely, and reduce the wear-outs of the measurement surface of thesubstrate and of the subject's surface.

Furthermore, an eddy-current probe according to the present inventioncomprises: a substrate having a first surface facing to a subject to betested and a second surface opposite to the first surface; an excitingcoil formed on the second surface, having a pair of current lines inparallel with each other through which exciting currents flow inopposite directions to each other during testing, for generating analternate magnetic field applied to the subject by the excitingcurrents; and at least one eddy-current sensor positioned on a centralaxis between the pair of current lines on the second surface of thesubstrate, for detecting a magnetic field generated newly from thesubject by an eddy-current induced by the alternate magnetic field.Especially, according to the present invention, the substrate includes alubricant layer, a DLC layer, or both of the DLC layer and the lubricantlayer formed on the first surface.

The lubricant layer, the DLC layer, or both of the DLC layer and thelubricant layer formed on the first surface of the substrate(measurement surface) can reduce the sticktion, and the wear-outs of themeasurement surface of the substrate and of the subject's surface.

Preferably, the at least one eddy-current sensor is a singleeddy-current sensor or a plurality of eddy-current sensors aligned onthe central axis between said pair of current lines.

It is also preferable that the at least one eddy-current sensor is amagnetoresistive element. In the case, the magnetoresistive element ispreferably a giant magnetoresistive element or a tunnel magnetoresistiveelement.

It is also preferable that the at least one eddy-current sensor is adetection coil.

Preferably, the exciting coil is a meander-type coil.

It is also preferable that the exciting coil comprises a coil conductorlayer formed on the substrate and an insulating layer covering the coilconductor layer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows a diagram schematically illustrating a configuration of antesting system using the eddy-current according to a preferredembodiment of the present invention;

FIG. 2 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to the embodiment in FIG. 1;

FIG. 3 shows a cross-sectional view taken along with line III-III inFIG. 2;

FIG. 4 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to another embodiment of thepresent invention;

FIG. 5 shows a cross-sectional view taken along with line V-V in FIG. 4;

FIG. 6 shows a cross-sectional view schematically illustrating aconfiguration according to an alternative of the embodiment in FIG. 4;

FIG. 7 shows a perspective view schematically illustrating a subject anda configuration of the ECT probe according to a further embodiment ofthe present invention;

FIG. 8 shows a cross-sectional view taken along with line VIII-VIII inFIG. 7;

FIG. 9 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 10 shows a cross-sectional view taken along with line X-X in FIG.9;

FIG. 11 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 12 shows a cross-sectional view taken along with line XII-XII inFIG. 11;

FIG. 13 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to an alternative of theembodiment in FIG. 11;

FIG. 14 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to another alternative of theembodiment in FIG. 11;

FIG. 15 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 16 shows a cross-sectional view taken along with line XVI-XVI inFIG. 15;

FIG. 17 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to an alternative of theembodiment in FIG. 15;

FIG. 18 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 19 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a further embodiment of thepresent invention;

FIG. 20 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 21 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 22 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 23 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 24 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 25 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 26 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 27 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention;

FIG. 28 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention; and

FIG. 29 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a diagram schematically illustrating a configuration of antesting system using the eddy-current according to a preferredembodiment of the present invention, FIG. 2 shows a perspective viewschematically illustrating a configuration of the ECT probe according tothe embodiment in FIG. 1, and FIG. 3 shows a cross-sectional view takenalong with line III-III in FIG. 2.

In these figures, reference numeral 10 indicates an ECT probe, 11indicates its flexible substrate formed of an insulative material suchas polyimide, 12 indicates a meander-type exciting coil including coilconductors formed as a planar pattern turned back on the oppositesurface 11 b to the measurement surface 11 a of the substrate 11, 13 and14 indicate a pair of electrode terminals formed on the substrate 11,which is connected electrically to both ends of the exciting coil 12, 15to 19 indicate thin-film chips bonded on the exciting coil 12, each ofwhich is mounted with a GMR element (eddy-current sensor) such as anSVMR element, 20 indicates a subject, 20 a indicates a defect such as aflaw and a crack appearing on the subject 20, 21 indicates a multiplexerconnected electrically to the each GMR element in the ECT probe 10,which applies these GMR elements with a sense current and takes outsignals from the each GMR element, 22 indicates a lock-in amplifier thatreceives the signals from the each GMR element through the multiplexer21 and detects the signal's level, 23 indicates a computer thatprocesses the input signals from the lock-in amplifier, displays theresults and so on, and 24 indicates a power supply for alternatemagnetic field, which provide the exciting coil 12 in the ECT probe 10with an alternate exciting current and provide the lock-in amplifier 22with the exciting current as reference signals, respectively.

The exciting coil 12 includes a coil conductor layer formed on theinsulative substrate 11 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 12 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 11, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 15 to 19 are aligned on a central axis of a pair ofcurrent lines 12 a and 12 b positioned at the center in the X directionon the exciting coil 12. These thin-film chips 15 to 19 are bonded onthe opposite surface to the subject 20 in the exciting coil 12.

Each of the thin-film chips 15 to 19 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, as understood from FIG. 3, thesubstrate 11 has a non-planar form curved along a traverse direction (Xdirection) where the measurement surface 11 a shows a waveform of asingle convex-surface. The thin-film chips 15 to 19 are mounted, via theexciting coil 12, on the opposite surface 11 b of the substrate 11,which is a single concave-surface corresponding to the singleconvex-surface.

Because the measurement surface 11 a on the substrate showing a waveformof a single convex-surface has a small facing/contact area with thesubject 20, the sticktion hardly occurs. Even if the sticktion occurs,much less external-force application should be needed to remove theprobe from the subject 20 against the sticktion. Consequently, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent. Further,because the thin-film chips 15 to 19 are mounted on the concave-surfaceof the opposite surface 11 b of the substrate 11, the distance betweenthe surface of the subject 20 and the GMR element does not increase, andtherefore, a high performance of resolution is provided.

FIG. 4 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to another embodiment of thepresent invention, and FIG. 5 shows a cross-sectional view taken alongwith line V-V in FIG. 4.

In these figures, reference numeral 41 indicates a flexible substrateformed of an insulative material such as polyimide, 42 indicate ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 41 b to themeasurement surface 41 a of the substrate 41, 43 and 44 indicate a pairof electrode terminals formed on the substrate 41, which is connectedelectrically to both ends of the exciting coil 42, and 45 and 46indicate thin-film chips bonded on the exciting coil 42, each of whichis mounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 42 includes a coil conductor layer formed on theinsulative substrate 41 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 42 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 41, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 45 and 46 are aligned on a central axis of two pairsof current lines 42 a and 42 b, and 42 c and 42 d positioned atdifferent locations from each other in the X direction on the excitingcoil 42. These thin-film chips 45 and 46 are bonded on the oppositesurface to the subject in the exciting coil 42.

Each of the thin-film chips 45 and 46 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, as understood from FIG. 5, thesubstrate 41 has a non-planar form curved along a traverse direction (Xdirection) where the measurement surface 41 a shows a waveform of twoconvex-surfaces. The thin-film chips 45 and 46 are mounted, via theexciting coil 42, on the opposite surface 41 b of the substrate 41,which has two concave-surface portions corresponding to the twoconvex-surface portions.

Because the measurement surface 41 a on the substrate showing a waveformof the two convex-surfaces has a small facing/contact area with thesubject, the sticktion hardly occurs. Even if the sticktion occurs, muchless external-force application should be needed to remove the probefrom the subject against the sticktion. Consequently, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent. Further,because the thin-film chips 45 and 46 are mounted respectively on thetwo concave-surfaces of the opposite surface 41 b of the substrate 41,the distance between the surface of the subject and the GMR element doesnot increase, and therefore, a high performance of resolution isprovided.

FIG. 6 shows a cross-sectional view schematically illustrating aconfiguration according to an alternative of the embodiment in FIG. 4.

According to the alternative, the substrate 41′ has a non-planar formcurved along a traverse direction (X direction) where the measurementsurface 41 a′ facing to the subject shows a waveform of a singleconvex-surface that has a planar central portion. The thin-film chips 45and 46 are mounted, via the exciting coil 42, at the different positionfrom each other on the opposite surface 41 b′ of the substrate 41′,which is a single concave-surface that has a planar central portioncorresponding to a single convex-surface that has a planar centralportion. The other configurations according to the alternative arealmost the same as those according to the embodiment in FIG. 4.

In the alternative, because the measurement surface 41 a′ on thesubstrate showing a waveform of a single convex-surface that has aplanar central portion has a small facing/contact area with the subject,the sticktion hardly occurs. Even if the sticktion occurs, much lessexternal-force application should be needed to remove the probe from thesubject against the sticktion. Consequently, a damage probability by thesticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent. Further, because thethin-film chips 45 and 46 are mounted on the single concave-surface thathas a planar central portion of the opposite surface 41 b′ of thesubstrate 41′, the distance between the surface of the subject and theGMR element does not increase, and therefore, a high performance ofresolution is provided.

FIG. 7 shows a perspective view schematically illustrating a subject anda configuration of the ECT probe according to a further embodiment ofthe present invention, and FIG. 8 shows a cross-sectional view takenalong with line VIII-VIII in FIG. 7.

In these figures, reference numeral 70 indicates a ECT probe, 71indicates a flexible substrate formed of an insulative material such aspolyimide, 72 indicates a meander-type exciting coil including coilconductors formed as the planar pattern turned back on the oppositesurface to the measurement surface of the substrate 71, 75 indicates aplurality of thin-film chips bonded on the exciting coil 72, each ofwhich is mounted with a GMR element (eddy-current sensor) such as anSVMR element, and 80 indicates a subject, respectively.

The thin-film chips 75 are aligned on a central axis of a pair ofcurrent lines positioned at the center in the X direction on theexciting coil 72. These thin-film chips 75 are bonded on the oppositesurface to the subject 80 in the exciting coil 72.

Each of the thin-film chips 75 includes a GMR element such as an SVMRelement for example, a pair of lead conductors connected electrically tothe GMR element, and a pair of electrode terminals connectedelectrically to the lead conductors, all of which are formed bythin-film technique on a chip substrate.

According to the present embodiment, as understood from FIG. 8, thesubstrate 71 has a non-planar form curved along a traverse direction (Xdirection) where the measurement surface facing to the subject 80 showsa waveform of a single convex-surface. Further, the substrate 71 hasflexibility where the substrate can curve flexibly along the curvedsurface of the subject 80. The thin-film chips 75 are mounted, via theexciting coil 72, on the opposite surface of the substrate 71, which isa single concave-surface corresponding to the single convex-surface.

The other configurations according to the present embodiment are almostthe same as those according to the embodiment in FIG. 1.

Because the measurement surface of the substrate showing a waveform ofthe single convex-surface has a small facing/contact area with thesubject 80, the sticktion hardly occurs. Even if the sticktion occurs,much less external-force application should be needed to remove theprobe from the subject 80 against the sticktion. Consequently, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent. Further,because the thin-film chips 75 are mounted on the single concave-surfaceof the opposite surface of the substrate 71, the distance between thesurface of the subject 80 and the GMR element does not increase, andtherefore, a high performance of resolution is provided.

FIG. 9 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention, and FIG. 10 shows a cross-sectional view takenalong with line X-X in FIG. 9. Here, FIG. 9 shows a view from the sideof the opposite surface to that of FIG. 2, that is, of the measurementsurface facing to the subject.

In these figures, reference numeral 91 indicates a flexible substrateformed of an insulative material such as polyimide, 92 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 91 b to themeasurement surface 91 a of the substrate 91, 93 and 94 indicate a pairof electrode terminals formed on the substrate 91, which is connectedelectrically to both ends of the exciting coil 92, and 95 to 99 indicatethin-film chips bonded on the exciting coil 92, each of which is mountedwith a GMR element (eddy-current sensor) such as an SVMR element,respectively.

The exciting coil 92 includes a coil conductor layer formed on theinsulative substrate 91 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 92 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 91, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 95 to 99 are aligned on a central axis of a pair ofcurrent lines positioned at the center in the X direction on theexciting coil 92. These thin-film chips 95 to 99 are bonded on theopposite surface to the subject in the exciting coil 92.

Each of the thin-film chips 95 to 99 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 91 has aplanar form, and a part of the measurement surface 91 a facing tosubject has a large number of, preferably much small, machined concavesand convexes 91 c such as a blasting rough surface or an embossedsurface.

Because the measurement surface 91 a of the substrate has a large numberof machined concaves and convexes 91 c, the sticktion hardly occurs.Accordingly, a damage probability by the sticktion is drasticallyreduced, and therefore, the durability and lifetime can be improved in alarge extent.

FIG. 11 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention, and FIG. 12 shows a cross-sectional view takenalong with line XII-XII in FIG. 11. Here, FIG. 11 shows a view from theside of the opposite surface to that of FIG. 2, that is, of themeasurement surface facing to the subject.

In these figures, reference numeral 111 indicates a flexible substrateformed of an insulative material such as polyimide, 112 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 111 b to themeasurement surface 111 a of the substrate 111, 113 and 114 indicate apair of electrode terminals formed on the substrate 111, which isconnected electrically to both ends of the exciting coil 112, and 115 to119 indicate thin-film chips bonded on the exciting coil 112, each ofwhich is mounted with a GMR element (eddy-current sensor) such as anSVMR element, respectively.

The exciting coil 112 includes a coil conductor layer formed on theinsulative substrate 111 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 112 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 111, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 115 to 119 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 112. These thin-film chips 115 to 119 are bonded on theopposite surface to the subject in the exciting coil 112.

Each of the thin-film chips 115 to 119 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 111 has aplanar form, and a part of the measurement surface 111 a facing tosubject has a large number of, preferably much small, grooves 111 cextended along a traverse direction (X direction) in the substrate 111.

Because the measurement surface 111 a on the substrate has a largenumber of machined grooves 111 c extended along the traverse direction,the sticktion hardly occurs. Accordingly, a damage probability by thesticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent.

FIG. 13 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to an alternative of theembodiment in FIG. 11. Here, FIG. 13 shows a view from the side of theopposite surface to that of FIG. 2, that is, of the measurement surfacefacing to the subject.

According to the present alternative, the entire substrate 111′ has aplanar form, and a part of the measurement surface 111 a ′ facing tosubject has a large number of, preferably much small, grooves 111 c ′extended along a longitudinal direction (Z direction) in the substrate111′. The other configurations according to the present alternative arealmost the same as those according to the embodiment in FIG. 11.

Because the measurement surface 111 a ′ on the substrate has a largenumber of machined grooves 111 c ′extended along the longitudinaldirection, the sticktion hardly occurs. Accordingly, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent.

FIG. 14 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to another alternative of theembodiment in FIG. 11. Here, FIG. 14 shows a view from the side of theopposite surface to that of FIG. 2, that is, of the measurement surfacefacing to the subject.

According to the present alternative, the entire substrate 111″ has aplanar form, and a part of the measurement surface 111 a ″ facing tosubject has a large number of, preferably much small, grooves 111 c ″extended along the oblique direction to a traverse direction (Xdirection) in the substrate 111″. The other configurations according tothe present alternative are almost the same as those according to theembodiment in FIG. 11.

Because the measurement surface 111 a ″ on the substrate has a largenumber of machined grooves 111 c ″ extended along the oblique direction,the sticktion hardly occurs. Accordingly, a damage probability by thesticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent.

FIG. 15 shows a perspective view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention, and FIG. 16 shows a cross-sectional view takenalong with line XVI-XVI in FIG. 15. Here, FIG. 15 shows a view from theside of the opposite surface to that of FIG. 2, that is, of themeasurement surface facing to the subject.

In these figures, reference numeral 151 indicates a flexible substrateformed of an insulative material such as polyimide, 152 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 151 b to themeasurement surface 151 a of the substrate 151, 153 and 154 indicate apair of electrode terminals formed on the substrate 151, which isconnected electrically to both ends of the exciting coil 152, and 155 to159 indicate thin-film chips bonded on the exciting coil 152, each ofwhich is mounted with a GMR element (eddy-current sensor) such as anSVMR element, respectively.

The exciting coil 152 includes a coil conductor layer formed on theinsulative substrate 151 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 152 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 151, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 155 to 159 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 152. These thin-film chips 155 to 159 are bonded on theopposite surface to the subject in the exciting coil 152.

Each of the thin-film chips 155 to 159 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 151 has aplanar form, and a part of the measurement surface 151 a facing to thesubject has a large number of, preferably much small, blind holes 151 c.

Because the measurement surface 151 a on the substrate has a largenumber of machined blind holes 151 c, the sticktion hardly occurs.Accordingly, a damage probability by the sticktion is drasticallyreduced, and therefore, the durability and lifetime can be improved in alarge extent.

FIG. 17 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to an alternative of theembodiment in FIG. 15.

According to the present alternative, the entire substrate 151′ has aplanar form, and a part of the measurement surface 151 a′ facing to thesubject has a large number of, preferably much small, through holes 151c′. The other configurations according to the present alternative arealmost the same as those according to the embodiment in FIG. 15.

Because the measurement surface 151 a′ on the substrate has a largenumber of through holes 151 c′, the sticktion hardly occurs.Accordingly, a damage probability by the sticktion is drasticallyreduced, and therefore, the durability and lifetime can be improved in alarge extent.

FIG. 18 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 181 indicates a flexible substrateformed of an insulative material such as polyimide, 182 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 181 b to themeasurement surface 181 a of the substrate 181, and 185 to 189 indicatethin-film chips bonded on the exciting coil 182, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 182 includes a coil conductor layer formed on theinsulative substrate 181 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 182 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 181, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 185 to 189 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 182. These thin-film chips 185 to 189 are bonded on theopposite surface to the subject in the exciting coil 182.

Each of the thin-film chips 185 to 189 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 181 has aplanar form, and a part of the measurement surface 181 a facing to thesubject is applied with a lubricant 181 d such as a lubricating oil. Theother configurations according to the present alternative are almost thesame as those according to the embodiment in FIG. 1 with the exceptionthat the substrate 181 has a planar form.

Because a part of the measurement surface 181 a on the substrate has alubricant layer 181 d, the sticktion hardly occurs. Accordingly, adamage probability by the sticktion is drastically reduced, andtherefore, the durability and lifetime can be improved in a largeextent.

FIG. 19 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 191 indicates a flexible substrateformed of an insulative material such as polyimide, 192 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 191 b to themeasurement surface 191 a of the substrate 191, and 195 to 199 indicatethin-film chips bonded on the exciting coil 192, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 192 includes a coil conductor layer formed on theinsulative substrate 191 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 192 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 191, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 195 to 199 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 192. These thin-film chips 195 to 199 are bonded on theopposite surface to the subject in the exciting coil 192.

Each of the thin-film chips 195 to 199 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 191 has aplanar form, and a part of the measurement surface 191 a facing to thesubject has a large number of, preferably much small, grooves 191 cextended along a traverse direction (X direction), a longitudinaldirection (Z direction) or an oblique direction to the traversedirection (X direction), and is applied with a lubricant 191 d such as alubricating oil. The other configurations according to the presentembodiment are almost the same as those according to the embodiment inFIG. 11, or the alternative in FIG. 13 or in FIG. 14.

Because a part of the measurement surface 191 a on the substrate has alarge number of grooves 191 c and a lubricant layer 191 d, the sticktionhardly occurs. Accordingly, a damage probability by the sticktion isdrastically reduced, and therefore, the durability and lifetime can beimproved in a large extent.

FIG. 20 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 201 indicates a flexible substrateformed of an insulative material such as polyimide, 202 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 201 b to themeasurement surface 201 a of the substrate 201, and 205 to 209 indicatethin-film chips bonded on the exciting coil 202, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 202 includes a coil conductor layer formed on theinsulative substrate 201 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 202 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 201, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 205 to 209 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 202. These thin-film chips 205 to 209 are bonded on theopposite surface to the subject in the exciting coil 202.

Each of the thin-film chips 205 to 209 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 201 has aplanar form, and a part of the measurement surface 201 a facing to thesubject has a large number of, preferably much small, blind holes 201 c,and is applied with a lubricant 201 d such as a lubricating oil. Theother configurations according to the present embodiment are almost thesame as those according to the embodiment in FIG. 15.

Because a part of the measurement surface 201 a on the substrate has alarge number of blind holes 201 c and a lubricant layer 201 d, thesticktion hardly occurs. Accordingly, a damage probability by thesticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent.

FIG. 21 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 211 indicates a flexible substrateformed of an insulative material such as polyimide, 212 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 211 b to themeasurement surface 211 a of the substrate 211, and 215 to 219 indicatethin-film chips bonded on the exciting coil 212, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 212 includes a coil conductor layer formed on theinsulative substrate 211 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 212 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 211, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 215 to 219 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 212. These thin-film chips 215 to 219 are bonded on theopposite surface to the subject in the exciting coil 212.

Each of the thin-film chips 215 to 219 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 211 has aplanar form, and a part of the measurement surface 211 a facing to thesubject has a large number of, preferably much small, through holes, andis applied with a lubricant 211 d such as a lubricating oil. The otherconfigurations according to the present embodiment are almost the sameas those according to the embodiment in FIG. 17.

Because a part of the measurement surface 211 a on the substrate has alarge number of through holes 211 c and a lubricant layer 211 d, thesticktion hardly occurs. Accordingly, a damage probability by thesticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent.

FIG. 22 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 221 indicates a flexible substrateformed of an insulative material such as polyimide, 222 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 221 b to themeasurement surface 221 a of the substrate 221, and 225 to 229 indicatethin-film chips bonded on the exciting coil 222, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 222 includes a coil conductor layer formed on theinsulative substrate 221 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 222 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 221, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 225 to 229 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 222. These thin-film chips 225 to 229 are bonded on theopposite surface to the subject in the exciting coil 222.

Each of the thin-film chips 225 to 229 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 221 has aplanar form, and a part of the measurement surface 211 a facing to thesubject is coated with a DLC layer 221 e. The other configurationsaccording to the present embodiment are almost the same as thoseaccording to the embodiment in FIG. 1 or the embodiment in FIG. 18 withthe exception that the substrate 221 has a planar form.

Because a part of the measurement surface 221 a on the substrate has aDLC layer 221 e, the sticktion hardly occurs. Accordingly, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent.

FIG. 23 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 231 indicates a flexible substrateformed of an insulative material such as polyimide, 232 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 231 b to themeasurement surface 231 a of the substrate 231, and 235 to 239 indicatethin-film chips bonded on the exciting coil 232, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 232 includes a coil conductor layer formed on theinsulative substrate 231 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 232 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 231, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 235 to 239 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 232. These thin-film chips 235 to 239 are bonded on theopposite surface to the subject in the exciting coil 232.

Each of the thin-film chips 235 to 239 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 231 has aplanar form, and a part of the measurement surface 231 a facing to thesubject has a large number of, preferably much small, grooves 231 cextended along a traverse direction (X direction), a longitudinaldirection (Z direction) or an oblique direction to the traversedirection (X direction), and is coated with a DLC layer 231 e. The otherconfigurations according to the present embodiment are almost the sameas those according to the embodiment in FIG. 11, or the alternative inFIG. 13 or in FIG. 14.

Because a part of the measurement surface 231 a on the substrate has alarge number of grooves 231 c and a DLC layer 231 e, the sticktionhardly occurs. Accordingly, a damage probability by the sticktion isdrastically reduced, and therefore, the durability and lifetime can beimproved in a large extent.

FIG. 24 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 241 indicates a flexible substrateformed of an insulative material such as polyimide, 242 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 241 b to themeasurement surface 241 a of the substrate 241, and 245 to 249 indicatethin-film chips bonded on the exciting coil 242, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 242 includes a coil conductor layer formed on theinsulative substrate 241 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 242 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 241, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 245 to 249 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 242. These thin-film chips 245 to 249 are bonded on theopposite surface to the subject in the exciting coil 242.

Each of the thin-film chips 245 to 249 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 241 has aplanar form, and a part of the measurement surface 241 a facing to thesubject has a large number of, preferably much small, blind holes 241 c,and is coated with a DLC layer 241 e. The other configurations accordingto the present embodiment are almost the same as those according to theembodiment in FIG. 15.

Because a part of the measurement surface 241 a on the substrate has alarge number of blind holes 241 c and a DLC layer 241 e, the sticktionhardly occurs. Accordingly, a damage probability by the sticktion isdrastically reduced, and therefore, the durability and lifetime can beimproved in a large extent.

FIG. 25 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 251 indicates a flexible substrateformed of an insulative material such as polyimide, 252 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 251 b to themeasurement surface 251 a of the substrate 251, and 255 to 259 indicatethin-film chips bonded on the exciting coil 252, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 252 includes a coil conductor layer formed on theinsulative substrate 251 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 252 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 251, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 255 to 259 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 252. These thin-film chips 255 to 259 are bonded on theopposite surface to the subject in the exciting coil 252.

Each of the thin-film chips 255 to 259 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 251 has aplanar form, and a part of the measurement surface 251 a facing to thesubject has a large number of, preferably much small, through holes 251c, and is applied with a DLC layer 251 e. The other configurationsaccording to the present embodiment are almost the same as thoseaccording to the alternative in FIG. 17.

Because a part of the measurement surface 251 a on the substrate has alarge number of through holes 251 c and a DLC layer 251 e, the sticktionhardly occurs. Accordingly, a damage probability by the sticktion isdrastically reduced, and therefore, the durability and lifetime can beimproved in a large extent.

FIG. 26 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 261 indicates a flexible substrateformed of an insulative material such as polyimide, 262 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 261 b to themeasurement surface 261 a of the substrate 261, and 265 to 269 indicatethin-film chips bonded on the exciting coil 262, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 262 includes a coil conductor layer formed on theinsulative substrate 261 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 262 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 261, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 265 to 269 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 262. These thin-film chips 265 to 269 are bonded on theopposite surface to the subject in the exciting coil 262.

Each of the thin-film chips 265 to 269 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 261 has aplanar form, and a part of the measurement surface 261 a facing to thesubject is coated with a DLC layer 261 e, and is applied with alubricant 261 d such as a lubricating oil. The other configurationsaccording to the present embodiment are almost the same as thoseaccording to the embodiment in FIG. 1 or the embodiment in FIG. 18 withthe exception that the substrate 261 has a planar form.

Because a part of the measurement surface 261 a on the substrate has aDLC layer 261 e and a lubricant layer 261 d, the sticktion hardlyoccurs. Accordingly, a damage probability by the sticktion isdrastically reduced, and therefore, the durability and lifetime can beimproved in a large extent.

FIG. 27 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 271 indicates a flexible substrateformed of an insulative material such as polyimide, 272 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 271 b to themeasurement surface 271 a of the substrate 271, and 275 to 279 indicatethin-film chips bonded on the exciting coil 272, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 272 includes a coil conductor layer formed on theinsulative substrate 271 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 272 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 271, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 275 to 279 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 272. These thin-film chips 275 to 279 are bonded on theopposite surface to the subject in the exciting coil 272.

Each of the thin-film chips 275 to 279 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 271 has aplanar form, and a part of the measurement surface 271 a facing to thesubject has a large number of, preferably much small, grooves 271 cextended along a traverse direction (X direction), a longitudinaldirection (Z direction) or an oblique direction to the traversedirection (X direction), and is coated with a DLC layer 271 e, and isfurther applied with a lubricant 271 d such as a lubricating oil. Theother configurations according to the present embodiment are almost thesame as those according to the embodiment in FIG. 11, or the alternativein FIG. 13 or in FIG. 14.

Because a part of the measurement surface 271 a on the substrate has alarge number of grooves 271 c, a DLC layer 271 e and a lubricant layer271 d, the sticktion hardly occurs. Accordingly, a damage probability bythe sticktion is drastically reduced, and therefore, the durability andlifetime can be improved in a large extent.

FIG. 28 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 281 indicates a flexible substrateformed of an insulative material such as polyimide, 282 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 281 b to themeasurement surface 281 a of the substrate 281, and 285 to 289 indicatethin-film chips bonded on the exciting coil 282, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 282 includes a coil conductor layer formed on theinsulative substrate 281 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 282 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 281, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 285 to 289 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 282. These thin-film chips 285 to 289 are bonded on theopposite surface to the subject in the exciting coil 282.

Each of the thin-film chips 285 to 289 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 281 has aplanar form, and a part of the measurement surface 281 a facing to thesubject has a large number of, preferably much small, blind holes 281 c,and is coated with a DLC layer 281 c, and is further applied with alubricant 281 d such as a lubricating oil. The other configurationsaccording to the present embodiment are almost the same as thoseaccording to the embodiment in FIG. 15.

Because a part of the measurement surface 281 a on the substrate has alarge number of blind holes 281 c, a DLC layer 281 e and a lubricantlayer 281 d, the sticktion hardly occurs. Accordingly, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent.

FIG. 29 shows a cross-sectional view schematically illustrating aconfiguration of the ECT probe according to a still further embodimentof the present invention.

In this figure, reference numeral 291 indicates a flexible substrateformed of an insulative material such as polyimide, 292 indicates ameander-type exciting coil including coil conductors formed as theplanar pattern turned back on the opposite surface 291 b to themeasurement surface 291 a of the substrate 291, and 295 to 299 indicatethin-film chips bonded on the exciting coil 292, each of which ismounted with a GMR element (eddy-current sensor) such as an SVMRelement, respectively.

The exciting coil 292 includes a coil conductor layer formed on theinsulative substrate 291 and an insulating layer covering the coilconductor layer. An exciting part of the exciting coil 292 has aplurality of current lines that extend in parallel with each other to Zdirection on the substrate 291, and are turned back at both ends. Duringtesting, alternate exciting currents with opposite directions to eachother flow through the current lines adjacent to each other,respectively.

The thin-film chips 295 to 299 are aligned on a central axis of a pairof current lines positioned at the center in the X direction on theexciting coil 292. These thin-film chips 295 to 299 are bonded on theopposite surface to the subject in the exciting coil 292.

Each of the thin-film chips 295 to 299 includes a GMR element such as anSVMR element for example, a pair of lead conductors connectedelectrically to the GMR element, and a pair of electrode terminalsconnected electrically to the lead conductors, all of which are formedby thin-film technique on a chip substrate.

According to the present embodiment, the entire substrate 291 has aplanar form, and a part of the measurement surface 291 a facing to thesubject has a large number of, preferably much small, through holes 291c, and is coated with a DLC layer 291 c, and is further applied with alubricant 291 d such as a lubricating oil. The other configurationsaccording to the present embodiment are almost the same as thoseaccording to the alternative in FIG. 17.

Because a part of the measurement surface 291 a on the substrate has alarge number of through holes 291 c, a DLC layer 291 e and a lubricantlayer 291 d, the sticktion hardly occurs. Accordingly, a damageprobability by the sticktion is drastically reduced, and therefore, thedurability and lifetime can be improved in a large extent.

In the above-mentioned embodiments, the thin-film chip includes the GMRelement such as the SVMR element. However, it is evident that thethin-film chip may include a TMR element instead of the GMR element,which has higher sensitivity than the GMR element.

Further, it is also evident that the detection coil with highsensitivity may be used instead of the GMR element.

All the foregoing embodiments are by way of example of the presentinvention only and not intended to be limiting, and many widelydifferent alternations and modifications of the present invention may beconstructed. Accordingly, the present invention is limited only asdefined in the following claims and equivalents thereto.

The eddy-current probe according to the present invention is extremelyuseful for a remarkably fine nondestructive testing such as aninspection of the micro-defects, the cracks, the scratches and so on inan object's surface and inside and an inspection of the micropatterns ona printed circuit board, as well as nondestructive testing of distortedsurfaces of important metal machine parts of a nuclear power plant, anaircraft and so on, such as turbine blades, various pipes and airplanewings.

1. An eddy-current probe comprising: a substrate having a first surfacefacing to a subject to be tested and a second surface opposite to saidfirst surface; an exciting coil formed on said second surface, having apair of current lines in parallel with each other through which excitingcurrents flow in opposite directions to each other during testing, forgenerating an alternate magnetic field applied to said subject by saidexciting currents; at least one eddy-current sensor positioned on acentral axis between said pair of current lines on said second surfaceof said substrate, for detecting a magnetic field generated newly fromsaid subject by an eddy-current induced by said alternate magneticfield; and said first surface of said substrate being a surface withmachined portions for reducing an occurrence probability of sticktion ofsaid first surface to said subject.
 2. The eddy-current probe as claimedin claim 1, wherein said surface with machined portions is a surfacehaving a plurality of concaves and convexes.
 3. The eddy-current probeas claimed in claim 2, wherein said surface having a plurality ofconcaves and convexes is a rough surface or an embossed surface.
 4. Theeddy-current probe as claimed in claim 2, wherein a lubricant layer isformed on said first surface having a plurality of concaves andconvexes.
 5. The eddy-current probe as claimed in claim 2, wherein adiamond-like carbon layer is formed on said first surface having aplurality of concaves and convexes.
 6. The eddy-current probe as claimedin claim 2, wherein a diamond-like carbon layer and a lubricant layerare formed on said first surface having a plurality of concaves andconvexes.
 7. The eddy-current probe as claimed in claim 1, wherein saidsurface with machined portions is a surface having a plurality ofgrooves.
 8. The eddy-current probe as claimed in claim 7, wherein saidgrooves are extended along a traverse direction of said substrate. 9.The eddy-current probe as claimed in claim 7, wherein said grooves areextended along a longitudinal direction of said substrate.
 10. Theeddy-current probe as claimed in claim 7, wherein said grooves areextended along an oblique direction to said traverse direction of saidsubstrate.
 11. The eddy-current probe as claimed in claim 7, wherein alubricant layer is formed on said first surface having a plurality ofgrooves.
 12. The eddy-current probe as claimed in claim 7, wherein adiamond-like carbon layer is formed on said first surface having aplurality of grooves.
 13. The eddy-current probe as claimed in claim 7,wherein a diamond-like carbon layer and a lubricant layer are formed onsaid first surface having a plurality of grooves.
 14. The eddy-currentprobe as claimed in claim 1, wherein said surface with machined portionsis a surface having a plurality of holes.
 15. The eddy-current probe asclaimed in claim 14, wherein said holes are blind holes.
 16. Theeddy-current probe as claimed in claim 14, wherein said holes arethrough holes.
 17. The eddy-current probe as claimed in claim 14,wherein a lubricant layer is formed on said first surface having aplurality of holes.
 18. The eddy-current probe as claimed in claim 14,wherein a diamond-like carbon layer is formed on said first surfacehaving a plurality of holes.
 19. The eddy-current probe as claimed inclaim 14, wherein a diamond-like carbon layer and a lubricant layer areformed on said first surface having a plurality of holes.